Process feed management for semiconductor substrate processing

ABSTRACT

Embodiments related to managing the process feed conditions for a semiconductor process module are provided. In one example, a gas channel plate for a semiconductor process module is provided. The example gas channel plate includes a heat exchange surface including a plurality of heat exchange structures separated from one another by intervening gaps. The example gas channel plate also includes a heat exchange fluid director plate support surface for supporting a heat exchange fluid director plate above the plurality of heat exchange structures so that at least a portion of the plurality of heat exchange structures are spaced from the heat exchange fluid director plate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application is a continuation of U.S. patent application Ser. No.14/660,755 filed on Mar. 17, 2015entitled “PROCESS FEED MANAGEMENT FORSEMICONDUCTOR SUBSTRATE PROCESSING,” which is a continuation of andclaims priority to U.S. patent application Ser. No. 13/284,642 entitled“PROCESS FEED MANAGEMENT FOR SEMICONDUCTOR SUBSTRATE PROCESSING,” filedOct. 28, 2011, the disclosures of which are hereby incorporated hereinby reference.

BACKGROUND

Supplying process reactants to semiconductor processing tools can bedifficult. For example, ambient gases may diffuse into low pressureportions of the process tool, potentially contaminating processreactants. Further, some process reactants may condense on variousprocess tool surfaces under some processing conditions. Contaminationand/or condensation of process reactants may lead to substrate qualityproblems as well as potential process control problems.

SUMMARY

Various embodiments are disclosed herein that relate to managing theprocess feed conditions for a semiconductor process module. For example,one embodiment provides a gas channel plate for a semiconductor processmodule. The example gas channel plate includes a heat exchange surfaceincluding a plurality of heat exchange structures separated from oneanother by intervening gaps. The example gas channel plate also includesa heat exchange fluid director plate support surface for supporting aheat exchange fluid director plate above the plurality of heat exchangestructures so that at least a portion of the plurality of heat exchangestructures are spaced from the heat exchange fluid director plate.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used to limit the scope of the claimed subject matter. Furthermore,the claimed subject matter is not limited to implementations that solveany or all disadvantages noted in any part of this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically shows a semiconductor process module according toan embodiment of the present disclosure.

FIG. 2 schematically shows an exploded isometric view of a portion ofthe semiconductor process module of FIG. 1

FIG. 3 schematically shows a larger isometric view taken along line 3 ofthe portion of the semiconductor process module shown in FIG. 2.

FIG. 4 schematically shows a cross-section taken along line 4 of theportion of the semiconductor process module shown in FIG. 3.

FIG. 5 schematically shows a larger isometric view taken along line 5 ofthe portion of the semiconductor process module shown in FIG. 3.

FIG. 6 schematically shows a cross-section taken along line 6 of theportion of the semiconductor process module shown in FIG. 5.

FIG. 7 schematically shows a larger isometric view taken along line 7 ofthe portion of the semiconductor process module shown in FIG. 2.

FIG. 8 schematically shows a cross-section taken along line 8 of theportion of the semiconductor process module shown in FIG. 7.

FIG. 9 schematically shows a cross-section taken along line 9 of theportion of the semiconductor process module shown in FIG. 7.

FIG. 10 schematically shows a sectioned isometric view of a showerheadvolume profile according to an embodiment of the present disclosure.

FIG. 11 schematically shows a sectioned isometric view of a showerheadvolume profile according to another embodiment of the presentdisclosure.

FIG. 12 schematically shows a sectioned isometric view of a two-pieceshowerhead according to an embodiment of the present disclosure.

FIG. 13 schematically shows a heat exchange fluid channel formed above agas channel plate according to an embodiment of the present disclosure.

FIG. 14 schematically shows a blower and duct for providing air to aheat exchange plenum assembly according to an embodiment of the presentdisclosure.

FIG. 15 schematically shows an exploded isometric view of a heatexchange plenum assembly according to an embodiment of the presentdisclosure.

FIG. 16 schematically shows a sectioned isometric view of air flowdistribution from a heat exchange plenum assembly to a heat exchangefluid channel formed above a gas channel plate according to anembodiment of the present disclosure.

FIG. 17 shows a flowchart for a method of processing a semiconductorsubstrate in a semiconductor process module according to an embodimentof the present disclosure.

DETAILED DESCRIPTION

Modem semiconductor devices may include integrated structures formed bythe deposition of films in high-aspect ratio cavities or under lowthermal budget conditions. Typical chemical vapor deposition (CVD),thermal growth, and/or physical vapor deposition (PVD) approaches maynot be suited to the process integration constraints for suchstructures. Atomic layer deposition (ALD) processes are sometimes usedto address these challenges. In ALD processes, thin layers of film aredeposited by alternately adsorbing two or more reactants to thesubstrate without supplying the reactants to the substrate processenvironment concurrently. By supplying each reactant separately, onlydeposited film layers and the surface active species of one reactantchemisorbed to those film layers are present on the substrate when theother reactant is supplied. Consequently, highly conformal films may beformed on the substrate surface, even in high-aspect ratio features.

The layer-by-layer nature of ALD processes may present challenges toenhance substrate throughput during manufacturing. For example, someapproaches to increase throughput include selecting process reactantsbased on reactivity characteristics that may enhance surfacedecomposition reactions on the substrate relative to other processreactants. However, the presence of ambient gases, such as oxygen and/orwater vapor, may lead to increases in gas phase decomposition as thereactivity of process reactants increases, potentially leading tosubstrate non-uniformity defects, small particle defects that maydecorate the substrate surface, and/or film composition contamination.

Other approaches to enhance throughput include supplying the substratewith a quantity of reactant suitable to provide acceptable substratecoverage of surface active species in a short-duration,high-concentration pulse. However, because some process reactants, suchas those including metals, may have higher molecular weights than thecarrier gases with which they may be mixed, it may be more difficult todistribute the process reactant on the substrate surface with suitablecoverage as pulse duration decreases. Consequently, cross-substrateconcentration gradients may form in the gas phase above the substrateduring process reactant exposure phases that may lead to substratenon-uniformity defects. In some settings, process reactants may condenseon process surfaces even under vacuum conditions. Such reactantcondensation upstream of the substrate may lead to small particle defectdecoration on the substrate surface. Additionally or alternatively, someprocess reactants may undergo gas phase or surface decompositionupstream of the substrate, potentially leading to film contamination orother process quality problems. While the problems that may result fromprocess reactants like those described above, such as organometallicreactants having low vapor pressures, are described herein in thecontext of ALD processes, it will be understood that similar issues mayexist for some process reactants used m some low-pressure CVD depositionprocesses, low-pressure etch processes, and so on.

The disclosed embodiments relate to hardware and methods for managingthe process feed conditions for a semiconductor process module. Forexample, one embodiment provides a network of purge gas channelsincluded in a gas channel plate or a showerhead for a semiconductorprocess module. The example purge gas channels fluidly communicate withan ambient environment via gaps positioned between the ambientenvironment and a gasket sealing the gas channel plate or the showerheadto another portion of the semiconductor process module. Consequently,ambient gas diffusion or permeation across the gasket and into the lowpressure reactor may be mitigated, potentially reducing film impuritiesand/or particle defects.

Another embodiment provides a semiconductor process module including ashowerhead volume upstream of a substrate. The example showerhead volumeincludes contours configured to form a radially symmetric profile withinthe showerhead volume with respect to an axial centerline of a processfeed inlet opening into the showerhead volume. The example showerheadvolume contours are shaped so that opposing surfaces of thesemiconductor process module forming the outer edges of the showerheadvolume are closer to one another than those same surfaces at a centralregion of the showerhead volume. Thus, though process feed isdistributed to the substrate via showerhead gas distribution holesdistributed across the showerhead, the process feed velocity may remainapproximately constant as the radial distance from the process feedinlet increases, potentially enhancing substrate uniformity.

Another embodiment provides a heat exchanger for a showerhead volume ofa semiconductor process module. The example heat exchanger includes aheat exchanger fluid director plate and a gas channel plate. The examplegas channel plate includes a plurality of heat exchange structuresseparated from one another by intervening gaps. The example heatexchange fluid director plate is supported above a heat exchange surfaceof the gas channel plate to form a heat exchange fluid channel intowhich the plurality of heat exchange structures protrude so that heatexchange fluid may flow between and above a portion of the heat exchangestructures. Consequently, condensation of process reactants within theshowerhead volume may potentially be reduced, as may gas phase and/orsurface reaction of process reactants upstream of the substrate. Inturn, defect generation caused by gas phase and/or condensed phasereactions may potentially be avoided. It will be understood that thevarious embodiments described herein are not intended to be limited tosolving the example problems referenced within this disclosure, whichare provided for illustrative purposes.

The disclosed embodiments may be fabricated from virtually any suitablematerials. For example, various structural portions may be fabricatedfrom aluminum, titanium, and/or stainless steel that may providesuitable mechanical, thermal, and/or chemical properties relevant to aparticular portion of a selected embodiment. Other portions may be madefrom suitable ceramics or polymers. For example, various gaskets mayinclude synthetic elastomer and/or fluoroelastomer materials that mayprovide enhanced chemical resistance to some the process feeds, such ashalogenated inorganic compounds, relative to alternative sealingmaterials. Accordingly, it will be understood that descriptions ofexample materials or fabrication techniques are provided forillustrative purposes alone. Such descriptions are not intended to belimiting.

FIG. 1 schematically shows a cross-section of an embodiment of asemiconductor process module 100. Semiconductor process module 100 maybe used for processing semiconductor substrates via any suitableprocess, e.g., film deposition, film etch, and the like. While theembodiment of semiconductor process module 100 depicted in FIG. 1 showsa single module, it will be appreciated that any suitable number ofprocess modules may be included in a processing tool so that substratesmay be transferred between process modules without being exposed toambient conditions. For example, some processing tools may include justone module while other processing tools may include two or more modules.While not shown in FIG. 1, various load locks, load ports, and substratetransfer handling robots may be used to transfer substrates betweenambient conditions and semiconductor process module 100 before, during,and after substrate processing.

As shown in FIG. 1, semiconductor process module 100 includes a lowpressure reactor 102 for processing semiconductor substrates. Theprocess feed is supplied to reactor 102 via a pulse valve manifold 104.Pulse valve manifold 104 delivers the process feeds, including reactantgases and/or inert gases, to reactor 102 via suitable valves anddistribution plumbing that manage the flow of the process feed duringvarious portions of substrate processing and/or module maintenanceprocessing events. The process feed is supplied from pulse valvemanifold 104 to reactor 102 via a process feed inlet 106.

Process feed inlet 106 opens into a central region of showerhead volume108 formed between a gas channel plate 110 and a showerhead 112. Forexample, in some embodiments, an axial centerline of process feed inlet106 may be aligned with a central axis of showerhead volume 108, so thatprocess feed may potentially be uniformly distributed radially withinshowerhead volume 108. Showerhead volume 108 provides a space for theprocess feed flow to develop upon exit from process feed inlet 106,potentially providing time and space for the velocity and flow of theprocess feed to adjust from the higher velocity conditions likelypresent within pulse valve manifold 104 to the comparatively lowervelocity conditions likely selected for substrate processing. In someembodiments, showerhead volume 108 may enclose a volume of between100,000 and 800,000 mm³. In one non-limiting example, showerhead volume108 may enclose a volume of between 300,000 and 500,000 mm³ upstream ofa single 300-mm diameter substrate.

In the embodiment shown in FIG. 1, the process feed flows radially fromprocess feed inlet 106 toward the outer edges of showerhead volume 108while being drawn downward toward showerhead distribution holes 114. Insome embodiments, the showerhead volume contours may be shaped so thatopposing surfaces of gas channel plate 110 and showerhead 112 that formshowerhead volume 108 are closer to one another at the outer edges ofshowerhead volume 108 than those same surfaces at a central region ofshowerhead volume 108.

Showerhead distribution holes 114 direct the process feed towardsubstrate process environment 116 where substrate processing occurs. Asusceptor 118 supports a substrate (not shown) within substrate processenvironment 116 during processing operations. Susceptor 118 may includea heater used to adjust a temperature of the substrate before, during,and/or after substrate processing. Susceptor 118 is mounted on anelevator 120 so that the substrate may be raised and lowered withinlower reactor 122 to facilitate substrate transfer in and out ofsemiconductor process module 100. A lift pin 124 is included to raiseand lower the substrate from susceptor 118 during substrate transferoperations.

Portions of unreacted process feed, carrier gases, and gases producedduring substrate processing are exhausted from substrate processenvironment 116 via process exhaust outlet 126. In the embodiment shownin FIG. 1, the process exhaust outlet 126 is formed at least in part bya gap extending around an outer circumference of substrate processenvironment 116 between showerhead 112 and flow control ring 128. Thus,in the depicted embodiment, a portion of process exhaust flows in radialdirection away from a center of substrate process environment 116 towardthe process exhaust outlet 126. Other portions of the process exhaustmay also flow into lower reactor 122, sealed to showerhead 112 via purgeplate 130 with a gasket, via a gap formed between a susceptor 120 andflow control ring 128.

Pressure within reactor 102 is controlled at least in part by one ormore pressure control devices (not shown), such as a throttle valve,fluidly coupled with upper reactor exhaust 132 and lower reactor exhaust134. However, it will be appreciated that pressure within reactor 102may also be controlled by suitable manipulation of various gas feeds toand bypasses around reactor 102. Accordingly, such feeds and bypassesmay also be considered pressure control devices within the scope of thepresent disclosure.

FIG. 2 schematically shows an exploded isometric view of portions of theembodiment of semiconductor process module 100 shown in FIG. 1. As shownin FIG. 2, a system process controller 202 (described in more detailbelow) for controlling various aspects of semiconductor process module100 is provided. System process controller 202 and pulse valve manifold104 are shown in FIG. 2 as being mounted above gas channel plate 110,showerhead 112, and a heat exchange plenum assembly 204 (described inmore detail below) via a support plate 206. A lift point 208 is providedfor raising portions of semiconductor process module 100, such as pulsevalve manifold 104, for maintenance procedures.

FIG. 2 also shows a plurality of showerhead access covers 210 positionedaround showerhead 112. Though not shown in FIG. 2, it will beappreciated that other suitable covers may be provided to shield accessto portions of pulse valve manifold 104, portions of upper reactor 104,and/or portions of lower reactor 102. Such access covers may includeventilation ports to permit the passage of air while generallyrestricting casual tool and/or user access.

FIG. 3 schematically shows a sectioned isometric view of gas channelplate 110 and showerhead 112 taken along line 3 of the embodiment shownin FIG. 2. As shown in FIG. 3, gas channel plate 110 is connected toshowerhead 112 by a plurality of clips 302 adapted to maintain apredetermined gap 304 between gas channel plate 110 and showerhead 112.Retaining gas channel plate 110 and showerhead 112 with clips 302 mayhelp to maintain a relative position between the respective parts whensemiconductor process module 100 is at ambient pressure.

When semiconductor process module 100 is under vacuum, ambient gases,such as oxygen and water vapor, may diffuse into low pressureenvironments like showerhead volume 108 and/or process environment 116,potentially contaminating the process feed, generating small particledefects, causing film contamination, impurity incorporation, and/orsubstrate non-uniformity defects. As used herein, a low pressureenvironment refers to portions of semiconductor process module 100 thatexperience sub-ambient pressure during process and/or maintenanceoperations. For example, showerhead volume 108 may exhibit a pressurewithin a range of 0.5 to 20 Torr in some non-limiting process settings.As another example, process environment 116 may experience a pressurewithin a range of 0.5 to 5 Torr in some non-limiting process settings.By reducing the pressure below an ambient pressure within showerheadvolume 108 or process environment 116, a low pressure environment iscreated within that respective portion of semiconductor process module100.

In some embodiments, gap 304 may act as an exit path for purge gasesused to dilute the concentration of ambient gases, reducing theirchemical potential for permeation from the outer perimeter (e.g., froman ambient side) of a gasket positioned between showerhead 112 and gaschannel plate 110. For example, FIG. 3 shows a purge gas inlet 306fluidly connected to a network of purge gas channels that that supplypurge gas to gap 304. As shown in FIG. 3, a suitable purge gas, likenitrogen, argon, helium, or the like, may be delivered via annular purgechannel 308 and a plurality of vertical purge channels 310 to form anear-continuous annular curtain of dry gas emerging from gap 304.Consequently, moisture and/or oxygen permeation across a seal betweenshowerhead 112 and gas channel plate 110 into reactor 102 may bemitigated, potentially reducing film impurities and/or particle defects.

FIG. 4 shows a cross-section taken along line 4 of the embodiment ofFIG. 3 illustrating a portion of a purge gas channel 400. Purge gaschannel 400 fluidly communicates with an ambient environment via gap 304at a location between the ambient environment and a gasket 402 disposedbetween showerhead 112 and gas channel plate 110. So positioned, apositive flow of purge gas from purge gas inlet 306 toward gap 304 mayprevent the diffusion of ambient gas toward and/or across gasket 402 andinto substrate process environment 116.

As shown in FIG. 4, purge gas channel 400 receives purge gas via ahorizontal purge feed 404 from purge gas inlet 306 and distributes thepurge gas around gas channel plate 110 via annular purge channel 308.Portions of the purge gas are diverted to vertical purge channels 310formed at intervals around the outer edge of gas channel plate 110.Vertical purge channels 310 are connected to horizontal purge channels406 at preselected intervals. Almost any suitable number of verticalpurge channels 310 may be provided at virtually any suitable interval.In some embodiments, eighteen vertical purge channels 310 may be evenlyspaced around annular purge channel 308. Horizontal purge channelsdirect the purge gas to gap 304, where the gas emerges into the ambientenvironment.

The purge gas channels described herein may be formed in almost anysuitable manner. Non-limiting examples of techniques for forming thevarious annular purge gas channels include milling and/or casting. Thevarious vertical purge gas channels may also be formed by drilling,casting, or other suitable techniques. It will be understood that thefabrication of the purge gas channels may leave openings that may resultin fugitive emissions of purge gas, potentially leading to pressure dropwithin the purge system and/or reduced flow rate from gap 304. In someembodiments, some or all of these openings may be fitted with removableand/or permanent closures or seals. For example, FIG. 4 depicts aflexible cord or gasket 408 that may seal an opening above annular purgechannel 308 and a cap 410 used to seal horizontal purge feed 404 in someembodiments. Such seals and caps may avoid or reduce fugitive emissionsof purge gas from openings used to fabricate the purge gas channels.

Ambient gases may also contaminate the low pressure environment bydiffusion from confined spaces after maintenance activity. Such “virtualleaks” can be difficult to trace, as the ambient gas results from gastrapped in so-called “dead volumes,” or volumes that are exposed to thelow pressure environment but that are not readily purged or pumped down.Thus, in some embodiments, some seals and gaskets may be positionedwithin a preselected distance of a low pressure environment such asshowerhead volume 108, process environment 116, suitable portions of theprocess feed upstream of showerhead volume 108 and suitable portions ofthe process exhaust downstream of process environment 116.

For example, FIG. 4 schematically shows gasket 402 positioned nearshowerhead volume 108 so that a low pressure environment formed withinshowerhead volume 108 may pump away residual ambient gases that may betrapped between mating surfaces of showerhead 112 and gas channel plate110 on a low pressure side of gasket 402. In some embodiments, a seal orgasket may be positioned within a range of 0.5 to 20 mm of a lowpressure environment. For example, in some non-limiting scenarios, agasket may be positioned within a range of 0.5 to 20 mm from a nearestouter edge of showerhead volume 108. In some other scenarios, a gasketmay be positioned within 4 mm of a nearest outer edge of showerheadvolume 108, within an acceptable tolerance.

As another example, in some embodiments, a seal or gasket sealingshowerhead volume 108 may be positioned within a preselected distance ofa showerhead distribution hole 114. In the embodiment shown in FIG. 4,gasket 402 is shown positioned near showerhead distribution hole 114.Positioning a gasket near showerhead distribution hole 114 may allow thelow pressure environment to rapidly pump away residual ambient gasesthat may be trapped between mating surfaces of showerhead 112 and gaschannel plate 110 on a low pressure side of gasket 402. In someembodiments, a seal or gasket may be positioned within a range of 0.5 to20 mm of a showerhead distribution hole 114. For example, in somenon-limiting scenarios, a gasket may be positioned 5 mm from a nearestshowerhead distribution hole 114, within an acceptable tolerance.

It will be appreciated that the approaches to managing ambient gasexposure to the low pressure environment may also be applied to otherportions of semiconductor process module 100. For example, purge gaschannels may also be included in other portions of semiconductor processmodule 100 to prevent ambient gas diffusion into substrate processenvironment 116 and/or low pressure environments. For example, in someembodiments, gas channel plate 110 may include a purge gas channelfluidly communicating with an ambient environment at a location betweenthe ambient environment and a gasket disposed between the gas channelplate and a pulse valve manifold positioned upstream of the gas channelplate.

FIG. 5 schematically shows a sectioned isometric view taken along line 5of the embodiment shown in FIG. 3. The embodiment shown in FIG. 5 showsan island 312 included in gas channel plate 110 used to mount pulsevalve manifold 104 to gas channel plate 110. As shown in FIG. 5, island312 includes a purge gas inlet 502 fluidly connected to a network ofpurge gas channels for distributing purge gas within island 312,including an annular purge channel 504 and a plurality of vertical purgechannels 506 that supply purge gas to the ambient environment viascallop-shaped gaps 508. In the embodiment depicted in FIG. 5, gaps 508positioned on an ambient side of a groove 510 adapted retain a gasketsealing island 312 to pulse valve manifold 104 potentially allow a purgegas to prevent ambient gases from permeating beyond the gasket and intothe low pressure environment.

FIG. 6 shows a cross-section taken along line 6 of the embodiment shownin FIG. 5, illustrating a portion of a purge gas channel 600. In theembodiment depicted, purge gas enters purge gas channel 600 via purgegas inlet 502 and is distributed to annular purge channel 504 via ahorizontal purge feed 602. Annular purge channel 504 distributes thepurge gas around island 312 to vertical purge channels 506, which divertportions of the purge gas toward gaps 508 at preselected intervals.Virtually any suitable number of vertical purge channels 506 may beprovided at almost any suitable interval. In some embodiments, sixvertical purge channels 506 may be evenly spaced around annular purgechannel 504 within island 312. As shown in FIG. 6, gaps 508 opening onto each vertical purge channel 506 permit purge gas to flow from purgegas channel 600 into the ambient environment at a position between theambient environment and sealing groove 510. FIG. 6 also depicts aflexible cord or gasket 604 that may seal an opening above annular purgechannel 504 and a cap 606 used to seal horizontal purge feed 602 in someembodiments. Such closures may avoid or reduce fugitive emissions ofpurge gas from openings used to fabricate the purge gas channels.

As another example, in some embodiments, a purge plate 130 may includepurge gas channels configured to prevent diffusion of ambient gasesacross gaskets sealing showerhead 112 to purge plate 130 and/or lowerreactor 122 to purge plate 130. For example, FIG. 7 shows a close-up ofthe embodiment of purge plate 130 shown in FIG. 2 taken along line 7. Asshown in FIG. 7, purge plate 130 includes a purge gas inlet 702 fluidlyconnected to a purge gas channel for distributing purge gas within purgeplate 130. For reference, the embodiment of purge plate 130 shown inFIG. 7 includes an upper surface 704 that interfaces with showerhead 112and a lower surface 706 that interfaces with lower reactor 122.

The purge gas channel shown in FIG. 7 includes an annular purge channel708 that is fluidly connected with a plurality of upwardly extendingvertical purge channels 710 that purge an ambient environment around agasket that seals upper surface 704 to showerhead 112. Annular purgechannel 708 is also fluidly connected with a plurality of downwardlyextending vertical purge channels 712 that purge an ambient environmentaround a gasket that seals lower surface 706 to lower reactor 122.

FIGS. 8 and 9 show cross-sections of the embodiment shown in FIG. 7taken along lines 8 and 9, respectively, illustrating portions of apurge gas channel 800. As shown in FIG. 8, purge gas enters purge gaschannel 800 via purge gas inlet 702 and is distributed to annular purgechannel 708 via a horizontal purge feed 802. Annular purge channel 708distributes the purge gas around purge plate 130 to vertical purgechannels 710 and 712, which divert portions of the purge gas toward gaps904, shown in FIGS. 9 as 904 a and 904 b, at preselected intervals.Virtually any suitable number of vertical purge channels 710 and 712 maybe provided at almost any suitable interval. In some embodiments,fourteen pairs of vertical purge channels 710 and 712 may be evenlyspaced around annular purge channel 708 within purge plate 130.

The embodiment shown in FIG. 9 shows gaps 904 a and 904 b couplingvertical purge channels 710 and 712 with the ambient environment atpositions between the ambient environment and gaskets provided to sealpurge plate 130 to adjacent surfaces. So positioned, gaps 904 a and 904b allow purge gas to sweep ambient gases away from the gaskets,potentially reducing permeation of ambient gases across those gaskets.Thus, purge gas flowing toward showerhead 112 will flow into gap 904 aat a position between the ambient environment and gasket 906 a, andpurge gas flowing toward lower reactor 122 will flow into gap 904 b at aposition between the ambient environment and gasket 906 b. FIGS. 8 and 9also depict a flexible cord or gasket 804 that may be used to seal anopening above annular purge channel 708 and a cap 806 that may be usedto seal horizontal purge feed 802 in some embodiments. Such closures mayavoid or reduce fugitive emissions of purge gas from openings used tofabricate the purge gas channels.

Process feed conditions within pulse valve manifold 104 may be adaptedto high speed, high pressure delivery of various process feed species toenhance substrate throughput and process speed. However, the rapidexpansion of process feed from these conditions into lower pressureconditions within showerhead volume 108 may potentially contribute tosubstrate process control problems and/or substrate quality excursions.For example, the process feed may experience transient cooling asprocess feed pressure drops in the vicinity of process feed inlet 106,potentially cooling surfaces surrounding process feed inlet 106. Inturn, this may cause condensation of some species of the process feedonto gas channel plate 110 near process feed inlet 106. Further, in somesettings, rapid expansion of the process feed may alter fluid mixing ofvarious reactants and inert species included in the process feed.Accordingly, in some embodiments, flow expansion structures may beprovided upstream of process feed inlet 106 to transition flowconditions within the process feed.

FIG. 10 schematically shows a sectioned isometric view of an embodimentof showerhead volume 108 formed between a diffusion surface 1012 of gaschannel plate 110 and showerhead 112. As shown in FIG. 10, an optionalflow expansion structure 1002 is provided upstream of process feed inlet106. In some embodiments, flow expansion structure 1002 may assist intransitioning and mixing higher velocity process feed flows exitingpulse valve manifold 104 (shown in FIG. 1) into slower velocity flowswithin showerhead volume 108 prior to distribution to processenvironment 116 via showerhead distribution holes 114. For example, inembodiments used in ALD processes, higher velocity pulse trains providedfrom pulse valve manifold 104 may be transitioned to a slower flowvelocity, at least in part, by transmission of the pulse train throughflow expansion structure 1002 before a subsequent expansion at theprocess feed inlet 106.

In the embodiment shown in FIG. 10, a centerline of a flow path includedin flow expansion structure 1002 is aligned with a centerline of processfeed inlet 106, so that fluid flow within flow expansion structure 1002may transition smoothly between a smaller upstream diameter and a largerdownstream diameter of flow expansion structure 1002. In someembodiments, an upstream diameter of flow expansion structure 1002 maybe approximately ⅝ of an inch and a downstream diameter may beapproximately 1 inch.

Virtually any suitable manner of expanding fluid flow within flowexpansion structure 1002 may be employed without departing from thescope of the present disclosure. As shown in FIG. 10, flow expansionstructure 1002 includes a concentric conical expansion shape formed onan inner surface 1006 of the flow expansion structure. Othernon-limiting examples of expansion shapes that may be formed on innersurface 1006 include bell-shaped expansion shapes, spiral expansionshapes, and the like, implementations of which may have upstream anddownstream diameters that may be concentric or eccentric with oneanother.

In the embodiment shown in FIG. 10, flow expansion structure 1002 isretained in gas channel plate 110 by a support ledge. A gasket 1050forms a seal between the support ledge and flow expansion structure1002. In some embodiments, gasket 1050 may be provided within apredetermined distance, such as a predetermined vertical distance, ofshowerhead volume 108. This may reduce an interfacial volume formedbetween mating surfaces of flow expansion structure 1002 and gas channelplate 110 on a low pressure side of gasket 1050, so that residualambient gases within that interfacial volume may be rapidly pumped away.

The example shown in FIG. 10 also depicts a gasket 1052 for sealing flowexpansion structure 1002 to pulse valve manifold 104 (not shown). Insome embodiments, gasket 1052 may be provided within a predetermineddistance of inner surface 1006. This may reduce an interfacial volumeformed between mating surfaces of flow expansion structure 1002 andpulse valve manifold 104 on a low pressure side of gasket 1052, whichmay potentially have the effect of rapidly pumping away residual ambientgases within that interfacial volume.

An optional impingement plate 1010 is shown in FIG. 10 that may protectshowerhead 108 from particles entrained in the process feed and/orassist in redirecting flow of process feed toward outer edges ofshowerhead volume 108. In some embodiments, impingement plate 1010 mayinclude holes aligned with showerhead distribution holes 114 to avoidformation of a shadow on center portion of a substrate disposed beneathimpingement plate 1010. As shown in FIG. 10, impingement plate may befastened to flow expansion structure 1002 by attachment to a retainingposition formed on inner surface 1006 and supported by one or moremounting structures 1008. In embodiments that exclude flow expansionstructure 1002, impingement plate 1010 may be attached to a suitableretaining position formed on an inner surface of process feed inlet 106.

As the process feed entering showerhead volume 108 via process feedinlet 106 expands, the velocity and flow orientation of the process feedchanges. In the embodiment shown in FIG. 10, the process feed spreadsradially from process feed inlet 106 toward outer edges of showerheadvolume 108 and showerhead distribution holes 114. Without wishing to bebound by theory, a radial pressure distribution may develop within theembodiment of showerhead volume 108 depicted in FIG. 10. This pressuredistribution may result from frictional forces as the process feed flowsacross diffusion surface 1012 and along an upper surface 1014 ofshowerhead 112. Radial pressure variation may also result from flow ofthe process feed out of showerhead volume 108 via showerheaddistribution holes 114. In turn, the process feed velocity may diminishas the distance from the process feed inlet 106 increases. Further,because various species within the process feed, such as reactant gasesand carrier gases, may have different molecular weights, diffusion ratesof those species within showerhead volume 108 may also be affected bylocal changes in pressure and gas density. Consequently, process feeddistribution to the substrate may be time and position variant,potentially leading to substrate non-uniformity defects.

Accordingly, in some embodiments, showerhead volume 108 may be contouredto enhance the flow of the process feed toward the radial edges ofshowerhead volume 108. In the embodiment shown in FIG. 10, diffusionsurface 1012 includes a radially symmetric profile with respect to anaxial centerline of the process feed inlet 106, so that diffusionsurface 1012 becomes closer to showerhead 112 as a distance from theaxial centerline of the process feed inlet 106 increases. In otherwords, the surfaces of gas channel plate 110 and showerhead 112 arecloser together at the outer edges of showerhead volume 108 than theyare at a central region of showerhead volume 108. Thus, as portions ofthe process feed are distributed via showerhead distribution holes 114,the process feed pressure within a fluid element moving radially outwardin showerhead volume 108 may remain approximately constant (within anacceptable tolerance). In turn, the velocity and concentrationcharacteristics of that fluid element may remain approximately constant.

While the embodiment in FIG. 10 shows contours of showerhead volume 108formed by diffusion surface 1012 of gas channel plate 110, it will beappreciated that some embodiments of showerhead volume 108 may includecontours formed in gas channel plate 110 and/or showerhead 112. Forexample, FIG. 11 schematically shows a sectioned isometric view ofanother embodiment of a showerhead volume 1100 formed between an uppersurface 1102 of showerhead 112 and a diffusion surface 1104 of gaschannel plate 110. In the embodiment shown in FIG. 11, upper surface1102 and diffusion surface 1104 are depicted as being parallel with oneanother, each surface including a radially symmetric profile withrespect to an axial centerline of the process feed inlet 106, so thatthe surfaces remain the same distance apart as a distance from the axialcenterline of the process feed inlet 106 increases. For example, in someembodiments, the distance between upper surface 1102 and a lower surface1150 of showerhead 112 defining an upper surface of process environment116 may be contoured to provide a preselected residence timedistribution of fluid flowing through showerhead distribution holes 114.In one non-limiting scenario, the distance between upper surface 1102and lower surface 1150 may be configured so that a residence time of afluid element flowing through a showerhead distribution hole 114 at thecenter of showerhead 112 (shown in FIG. 11 at 114 a) may be within tenpercent of a residence time of a fluid element flowing through ashowerhead distribution hole 114 positioned at an outer edge ofshowerhead 112 (shown at 114 b). In some settings, providing a constantresidence time (within an acceptable tolerance) for fluid flowing withinshowerhead distribution holes 114 may provide an approximately constantdelivery of reactive process feed to the surface of the substrate. Inturn, film deposition on the substrate may have enhanced thicknessuniformity. In still other embodiments, the diffusion surface of gaschannel plate 110 may be configured as a plane surface while a surfaceof showerhead 112 exposed to showerhead volume 108 may be contoured.

It will be appreciated that almost any suitable contour may be appliedto the showerhead volumes described herein without departing from thescope of the present disclosure. In some embodiments, a linearly-shapedradially symmetric profile may be formed on a portion of diffusionsurface 1012 and/or upper surface 1014 of the showerhead exposed toshowerhead volume 108, the linearly-shaped portion being disposed at anangle of between 0 and 5 degrees with respect to a reference planepositioned parallel with the substrate, such as a reference planedefining a widest portion of showerhead volume 108. For example, wherediffusion surface 1012 of gas channel plate 110 is contoured, thelinearly shaped portion may be formed at a negative angle of between 0and −5 degrees with respect to the reference plane. Where upper surface1014 of showerhead 112 is contoured, the linearly-shaped portion may beformed at a positive angle of between 0 and 5 degrees with respect tothe reference plane. Thus, in the embodiment shown in FIG. 10, diffusionsurface 1012 may have linear portion being disposed at an angle ofbetween 0 and −5 degrees with respect to a reference plane defining awidest portion of showerhead volume 108. In the embodiment shown in FIG.11, diffusion surface 1104 may have linear portion being disposed at anangle of between 0 and −5 degrees and upper surface 1102 may have linearportion being disposed at an angle of between 0 and +5 degrees with areference plane defining a widest portion of showerhead volume 108.

In some other embodiments, non-linear shapes may be formed into portionsof a diffusion surface and/or surfaces of a showerhead exposed to ashowerhead volume. For example, a portion of a diffusion surface mayexhibit a Gaussian-shaped or bell-shaped profile when viewed incross-section with respect to a reference plane positioned parallel to asubstrate, such as a reference plane defining a widest portion of ashowerhead volume. The various contours described herein may be formedover any suitable portion of the surfaces on which they are formed. Forexample, a contour formed on gas channel plate 110 and/or showerhead 112may be formed so that more than 95% of a surface of respective partexhibits a contour as described herein. Such contours may be formed inalmost any suitable manner. For example, the contours may be formed bymilling, casting, water jet cutting and/or laser cutting.

While the embodiments illustrated in the figures depict contouredsurfaces of example showerheads 112 and gas channel plates 110 that areintegrated into those respective items, it will be understood that insome embodiments contoured surfaces may be prepared as separate partsthat may be installed into and removed from their respective parts. Forexample, a first set of contours configured for a first processchemistry may be fitted to a gas channel plate 110 and/or a showerhead112 and later removed and replaced by a second set of contoursconfigured for a second process chemistry. This may allow for the rapiddevelopment and testing of various contours, for example using suitablethree-dimensional printing technology, without the replacement of entireshowerhead and/or gas channel plate assemblies.

As shown in FIGS. 10 and 11, showerhead 112 includes an annular exhaustpassage 1016 integrated within a single body. Annular exhaust passage1016 conducts the process exhaust from substrate process environment 116via process exhaust outlet 126 toward upper reactor exhaust 132 (asshown in FIG. 1).

In some embodiments, showerhead 112 may comprise an exhaust bodyconfigured to gather process exhaust that is separate from a body thatdistributes the process feed to the substrate. While a single-bodyshowerhead may potentially avoid some dead volumes formed near the outerregion of process environment 116, it will be appreciated that atwo-piece showerhead may offer other advantages. For example, atwo-piece showerhead 112 may allow differently profiled gas distributionbodies to be retrofitted to semiconductor process module 100 withoutmoving the exhaust collection body. In turn, re-calibration of a gapincluded in the process exhaust outlet 126 may be minor relative toprocedures for replacement of a single-body showerhead. FIG. 12schematically shows a section isometric view of an embodiment of atwo-piece showerhead 1200 including a gas distribution body 1202 and anannularly-shaped exhaust passage body 1204. As shown in FIG. 12, gasdistribution body 1202 includes a plurality of showerhead distributionholes 114 that distribute process feed to substrate process environment116. In the embodiment illustrated in FIG. 12, gas distribution body1202 is sealed to gas channel plate 110 via gasket 402 and to exhaustpassage body 1204 via gasket 1206. In some embodiments, gasket 1206 maybe positioned within a predetermined distance of process environment116, which may reduce the potential to trap ambient gases between gasdistribution body 1202 and exhaust passage body 1204. Exhaust passagebody 1204 is depicted as being sealed to purge plate 130 via gasket 906.Exhaust passage body 1204 includes an annular exhaust passage 1208 thatconducts process exhaust from process environment 116 via a gap formedbetween exhaust passage body 1204 and flow control ring 128.

Some low vapor pressure species included in process feeds supplied to asubstrate during substrate processing may condense on process surfacesunder some process conditions. For example, some species may condense onsurfaces within showerhead volume 108. Accordingly, in some embodiments,semiconductor process module 100 may include heat exchange structuresthermally coupled with showerhead volume 108 to adjust a temperature ofshowerhead volume 108. As used herein, being thermally coupled meansthat causing a change in temperature of at a heat exchange structurewill cause in a change in temperature at a surface of showerhead volume108 and vice-versa. Such temperature changes may be determined byvarious suitable techniques, such as infrared-or thermocouple-basedtemperature measurement techniques.

Such heat exchange structures may be included on a heat exchange surfaceof gas channel plate 110 that project into a heat exchange fluid. Otherheat exchange mechanisms, such as heaters, may also be thermally coupledwith showerhead volume 108. In turn, the temperature of showerheadvolume 108 may be adjusted during substrate processing so that processfeed condensation might potentially be avoided.

FIG. 13 schematically shows a close-up sectioned isometric view of aportion of an embodiment of gas channel plate 110. The embodiment shownin FIG. 13 depicts a heater groove included in gas channel plate 110,shown as heater groove 1302 a. A heater is included in the heatergroove, shown as heater 1304 a. Heater 1304 a provides heat to gaschannel plate 110 and to various surfaces in thermal contact with gaschannel plate 110, such as diffusion surface 1012, showerhead 112, andso on. In turn, condensation of process feed on diffusion surface 1012,flow expansion structure 1002 (shown in FIG. 10), and/or surfaces ofshowerhead volume 108 may potentially be avoided.

In some embodiments, a plurality of heaters may be provided in gaschannel plate 110 and showerhead 112, each controlled and poweredindependently from one another. For example, FIG. 13 shows a heater 1304b included in a heater groove 1302 b included in showerhead 112, heater1304 b being independent from and controlled separately from heater 1304a. Such an arrangement may be used to provide locational “zone” heatingto different portions of gas channel plate 110 and/or showerhead 112. Incombination with suitable heater control, zone heating permit thecreation of various temperature profiles within showerhead volume 108,showerhead 112, and gas channel plate 110. For example, gas channelplate 110 may be maintained at a lower temperature than showerhead 112,potentially preventing the accumulation of reaction byproducts inexhaust passage 1016. As another example, an arrangement ofannularly-nested independently-zoned heaters provided within gas channelplate 110 may allow the creation of a radial temperature profileextending from process feed inlet 106 toward the outer edges ofshowerhead volume 108. In turn, a central region of showerhead volume108 may be maintained at a comparatively higher temperature than theouter edges. This approach may potentially prevent condensation of alow-vapor pressure process species near process feed inlet 106, wherethe partial pressure of that species may be higher.

It will be understood that almost any suitable heater may be employedwithout departing from the scope of the present disclosure. In someembodiments, a flexible, cable-style heater may be provided that isconfigured to fit into a heater groove cut into gas channel plate 110.In some embodiments, a heater may include positive temperaturecoefficient materials configured to exhibit an increase in electricalresistance as temperature increases beyond a predetermined threshold,potentially reducing a risk of damage from temperature excursionsexceeding a predetermined ceiling relative to alternate style heaters.In the embodiment shown in FIG. 13, a heater is powered by electricitysupplied via a heater power connection 1306 which receives power from aheater controller via a heater power lead (shown as heater power lead1308 in FIGS. 10-12).

As introduced above, a heater groove is formed into gas channel plate110 and/or showerhead 112 to receive heat from a heater. Viewed as across-section, the sidewalls and bottom of a heater groove may makecontact with a heater at several locations, potentially improving heattransfer from heater relative to configurations where a heater makescontact on one side only, such as a heater resting on a surface. It willbe understood that the heater groove may be formed into gas channelplate 110 and/or showerhead 112 in virtually any suitable manner. Forexample, a heater groove may be milled and/or cast in some embodiments.Further, the heater groove may be shaped into virtually any suitableform. Non-limiting examples of shapes for a heater groove includeannular, serpentine paths having twists in at least two directions, andspiral paths that may or may not include branches. Such shapes may bearranged in almost any suitable position within gas channel plate 110and/or showerhead 112. For example, in some embodiments, heater groovesmay be positioned around a center of gas channel plate 110 and/orshowerhead 112 in a radially-symmetric arrangement.

In some embodiments, a retainer, shown as retainers 1310 a and 1310 b inFIG. 13, may be provided above heater 1304 a and 1304 b, respectively toapply a downward force to the heaters, potentially enhancing conductionbetween the heater groove and the heater. Further, in some of suchembodiments, the retainer may have heat transfer properties that furtherenhance heat transfer from the heater to gas channel plate 110 and/orshowerhead 112. For example, the retainer may be formed from a flexiblealuminum wire that may help conduct heat from a top surface of theheater to upper sidewalls of the heater groove.

Additionally or alternatively, in some embodiments, a temperature of gaschannel plate 110 may be adjusted using a suitable heat exchange fluidsupplied to heat exchange surfaces thereon. For example, in onescenario, cool air may be provided to moderate heating provided by theheater. In another scenario, warm air may be provided in place of or tosupplement heating provided by the heater. In each scenario, use of aheat exchange fluid may potentially smooth a thermal profile within gaschannel plate 110, so that hot and/or cold spots may be avoided.Virtually any suitable heat exchange fluid may be employed withoutdeparting from the scope of the present disclosure. Example suitableheat exchange fluids include, but are not limited to, gases like air andnitrogen, and liquids like water and heat transfer oils.

The embodiment depicted in FIG. 13 shows a plurality of heat exchangestructures 1312 separated from one another by gaps 1314 on a heatexchange surface 1316 of gas channel plate 110. Heat exchange structures1312 and gaps 1314 provide surface area for heat transfer and flowspace, respectively, for the heat exchange fluid.

It will be understood that heat exchange structures 1312 may have almostany suitable shape. The embodiment shown in FIG. 13 illustrates heatexchange structures 1312 as rectangularly-shaped, block-like structuresprojecting outward from heat exchange surface 1316. In some embodiments,heat exchange structures 1312 may be rectangular prisms that are 4 mmwide by 6 mm deep, within an acceptable tolerance, and that may haveheights that vary between 12 mm and 5 mm, so that the volume of heatexchange structures 1312 may vary with position as described in moredetail below. In some embodiments, gaps 1314 between heat exchangestructures 1312 may be approximately 6-7 mm wide. Additionally oralternatively, in some embodiments, gaps 1314 may be sized so that theyare no wider than one-half of a thickness of gas channel plate 110 at alocation on gas channel plate 110 where heat exchange structures 1312are positioned on gas channel plate 110. For example, in someembodiments, gaps 1314 may be sized according to a preselected ratiodefined as of a distance from a base of heat exchange structure 1312 todiffusion surface 1012 divided by a distance between adjacent heatexchange structures 1312. In some embodiments, the ratio may be greaterthan 2. For example, in some non-limiting scenarios, the ratio may be ina range between 3 and 5. Spacing heat exchange structures 1312 in thisway may avoid the formation of local hot and/or cold spots on diffusionsurface 1012. Other non-limiting heat exchange structures may includeoutwardly projected fin- or vane-shaped structures, honeycomb or meshtype baffled structures, and stacked plates.

In some embodiments, the volume of heat exchange structures 1312 mayvary according to a radial position on heat exchange surface 1316. Byvarying the volume according to radial position, it is possible that theamount of heat exchanged with the heat exchange fluid may be regulated.In the embodiment shown in FIG. 13, volume of heat exchange structures1312 increases with radial distance from a center of gas channel plate110. In one scenario according to this embodiment, less heat may betransferred to the heat exchange fluid near the center of the gaschannel plate relative to an amount of heat transferred near the outeredge. As a result, the center region of the diffusion surface may bemaintained at a comparatively higher temperature than the outer region.This approach may potentially prevent condensation of a low-vaporpressure process species near the process feed inlet, where the partialpressure of that species may be higher. Further, by transitioning to alower temperature near the outer edge of the diffusion surface, thedefect generation caused by gas phase reactions may potentially beavoided.

Heat exchange structures 1312 may be formed in any suitable manner andfrom any suitable material. For example, in some embodiments, heatexchange structures 1312 may be formed from aluminum, stainless steel,or titanium. Heat exchange structures 1312 may also be formed duringfabrication of gas channel plate 110 or added at a later time. Forexample, in some embodiments, heat exchange structures 1312 may bemachined into gas channel plate 110. In some other embodiments, heatexchange structures 1312 may be separate parts that may be added,subtracted, and rearranged on heat exchange surface 1316.

Heat exchange structures 1312 may be distributed in virtually anysuitable arrangement on gas channel plate 110. In the embodiment shownin FIG. 13, heat exchange structures 1312 are distributed in an annularregion, being radially arranged about a centerline of gas channel plate110. FIG. 3 and FIGS. 10-12 also show examples of heat exchangestructures 1312 arranged in circular patterns around process feed inlet106 in an annular region of gas channel plate 110.

As shown in FIG. 13, heat exchange structures 1312 project into a heatexchange fluid channel 1318 formed between heat exchange surface 1316and a heat exchange fluid director plate 1320 supported by a heatexchange fluid director plate support surface of gas channel plate 110.Thus, heat exchange fluid director plate 1320 and gas channel plate 110form a heat exchanger in the region of heat exchange fluid channel 1318,where heat exchange fluid director plate 1320 directs heat exchangefluid in between of heat exchange structures 1312 and also across thetops of at least a portion of heat exchange structures 1312.

The broad flow direction arrows illustrated in FIG. 13 depict an exampleflow of heat exchange fluid from an inlet 1324 into heat exchange fluidchannel 1318 where heat is exchanged with heat exchange structures 1312and then exhausted via an outlet 1326. By arranging heat exchangestructures 1312 in circular patterns around a center of gas channelplate 110 and directing the heat exchange fluid radially outward frominlet 1324, the heat exchange fluid flowing in heat exchange fluidchannel 1318 may flow co-currently with process feed flowing withinshowerhead volume 108. Consequently, a temperature of the process feedat the edge of showerhead volume 108 may be at least as great as atemperature of the heat exchange fluid exiting outlet 1326. This maypotentially avoid decomposition reactions within the process feed or onthe various surfaces defining showerhead volume 108.

While the flow direction arrows in FIG. 13 depict a flow of heatexchange fluid flowing radially outward in a circularly symmetric flow,it will be appreciated that virtually any suitable flow of heat exchangefluid may be employed without departing from the scope of the presentdisclosure. For example, in some embodiments, heat exchange fluid may bedirected radially inward from an outer edge of gas channel plate 110toward island 312. In some of such embodiments, the locations of inlet1324 and outlet 1326 may be reversed or otherwise suitable relocated. Instill other embodiments, heat exchange fluid may be directed in otherdirections around and/or across heat exchange surface 1316 so that itflows around and/or above heat exchange structures 1312.

In some embodiments, heat exchange fluid director plate 1320 may beincluded in heat exchange plenum assembly 204. Heat exchange plenumassembly 204 may provide ambient air as a heat exchange fluid to heatexchange surface 1316 via heat exchange fluid channel 1318 and thenexhaust the air back into the ambient environment. FIG. 14 schematicallyshows heat exchange plenum assembly 204 fluidly coupled to an embodimentof a blower 1402 by a flexible duct 1404. As shown in FIG. 14, blower1402 draws ambient air into intake 1406. The air is delivered byflexible duct 1404 to heat exchange plenum assembly 204. After passingover the heat exchange surface of the gas channel plate (not shown), theair is exhausted via exhaust holes 1408 into the ambient environment.

FIG. 15 schematically shows an exploded isometric view of an embodimentof a heat exchange plenum assembly 1500. As shown in FIG. 15, heatexchange plenum assembly 1500 includes a heat exchange fluid directorplate 1502 and a cover plate 1504. Heat exchange fluid director plate1502 includes a ring-shaped inner wall 1506, a ring-shaped outer wall1508 having a larger diameter than inner wall 1506, and a floor ring1510 that connects inner wall 1506 and outer wall 1508. Outer wall 1508includes opening 1512 to receive an inlet duct 1514 coupled to a blower(not shown). Inlet duct 1514 may include an optional switch 1516 used tocontrol the blower. Floor ring 1510 includes one or more openingsadjacent to inner wall 1506 that form inlets 1518.

In some embodiments, heat exchange fluid director plate 1502 isconfigured to be supported by a heat exchange fluid director platesupport surface included on gas channel plate 110. For example, in someembodiments, inner wall 1506 may be sized to fit snugly about and/or bephysically connected with island 312 of gas channel plate 110 forsupporting heat exchange fluid director plate 1502. Additionally oralternatively, in some embodiments, heat exchange fluid director plate1502 may be supported by island 312 via retainer 1520 and/or cover plate1504. By supporting heat exchange fluid director plate 1502 on island312, floor ring 1510 of heat exchange fluid director plate 1502 may bespaced from heat exchange surface 1316 of gas channel plate 110 so thatheat exchange fluid channel 1318 is formed above heat exchangestructures 1312. In turn, heat exchange fluid flowing in heat exchangefluid channel 1318 may flow between and above heat exchange structures1312 while flowing from inlet 1324 to outlet 1326, as shown in FIG. 13.Consequently, heat exchange fluid channel 1318 may accommodate heatexchange structures 1312 of varying heights as described above, and mayalso exchange heat along top surfaces of heat exchange structures 1312in contact with the heat exchange fluid.

Returning to FIG. 15, in some embodiments, one or more inlets 1518 maybe distributed around a base of inner wall 1506, so that heat exchangefluid may be supplied in an annular flow to gas channel plate 110. Insuch embodiments, the assembly of heat exchange fluid director plate1502 to cover plate 1504 via retainer 1520 and gasket 1522 forms anannular fluid flow space between inner wall 1506, outer wall 1508, coverplate 1504, and floor ring 1510. Thus, a heat exchange fluid may entervia opening 1512, travel around the annular flow space, and bedistributed to heat exchange fluid channel 1318 via inlets 1518 where itmay be redirected to travel radially outward toward the edges of gaschannel plate 110. For example, FIG. 16 schematically shows a sectionedisometric view of an embodiment of a portion of inlet duct 1514directing air toward an annular region 1602 formed between heat exchangefluid director plate 1502 and cover plate 1504. In the embodiment shownin FIG. 16, air flows radially outward from annular region 1602 via heatexchange fluid channel 1318 where it is exhausted from semiconductorprocess module 100 via exhaust holes 1408.

In some embodiments, heat exchange plenum assembly 1500 may include aflow restrictor positioned at outlet 1326 of heat exchange fluid channel1318 and configured to adjust the flow of heat exchange fluid therein.For example, FIG. 15 shows an embodiment of a flow restrictor ring 1524coupled to heat exchange fluid director plate 1502. As shown in FIG. 15,flow restrictor ring 1524 includes at least one restriction orifice 1526positioned to restrict flow through outlet 1326 and a clearance opening1528 configured to receive inlet duct 1514.

In some embodiments, the height of flow restrictor ring 1524 may beadjusted to vary the heat exchange characteristics of heat exchangefluid channel 1318. For example, given constant inlet and outletcross-sectional areas, increasing the height of flow restrictor ring1524 may increase the residence time of the heat exchange fluid withinthe heat exchange fluid channel 1318, potentially varying the radialtemperature profile of the gas channel plate. It will be appreciatedthat adjustments to the cross-sectional areas of the inlet and outletmay have a similar effect.

It will be appreciated that thermal management of showerhead volume 108may be systematically controlled by suitable temperatures sensors andheater and/or heat exchanger controllers in some embodiments. Thus, atemperature of gas channel plate 110, showerhead 112, flow expansionstructure 1002 and/or other portions of semiconductor process module 100thermally coupled with showerhead volume 108 may be adjusted duringsubstrate processing, potentially avoiding condensation and/or gas phasereactions of the process feed.

For example, FIG. 16 shows a temperature sensor 1604 included inshowerhead 112 and thermally coupled with showerhead volume 108. Whiletemperature sensor 1604 is physically positioned in showerhead 112 inthe embodiment shown in FIG. 16, it will be appreciated that one or moretemperature sensors 1604 may be provided at suitable locations inshowerhead 112 and/or gas channel plate 110. In some embodiments, aplurality of temperature sensors 1604 may be provided in variouslocations around showerhead 112 and/or gas channel plate 110 to providea thermal map of those parts and nearby portions of showerhead volume108. Virtually any suitable temperature sensor 1604 may be employedwithout departing from the scope of the present disclosure. Non-limitingexamples include bi-junction thermocouples and resistance thermometers.

Temperature information collected by one or more temperature sensors1604 may be provided to a thermal controller 1606 with which thetemperature sensors 1604 are electrically connected. In someembodiments, thermal controller 1606 may include a heater controller forcontrolling heaters 1304 and/or a blower controller for controllerblower 1402. In some embodiments, thermal controller 1606 may beincluded in system controller 202. In turn, thermal controller 1606 mayadjust power supplied to heater 1304 via heater power connection 1306.Additionally or alternatively, in some embodiments, thermal controller1606 may adjust operation of blower 1402 in response to temperatureinformation provided by temperature sensors 1604. For example, thermalcontroller 1606 may turn blower 1402 off or on or vary the blower speedto adjust an amount of air delivered.

It will be understood that the hardware described herein may be used toadjust the temperature of the process feeds a showerhead volume in asemiconductor processing module and, in turn, deliver the process feedsfrom the showerhead volume to the substrate to process a substratewithin the module.

FIG. 17 shows a flow chart for an embodiment of a method 1700 forprocessing a substrate in a processing environment of a reactor includedin semiconductor processing module. Method 1700 may be performed by anysuitable hardware and software. It will be appreciated that portions ofthe processes described in method 1700 may be omitted, reordered, and/orsupplemented without departing from the scope of the present disclosure.

Method 1700 includes, at 1702, supporting the substrate with a susceptorwithin the reactor and, at 1704, supplying process feed to the reactorvia a showerhead positioned above the substrate. For example, in an ALDprocess, the process feed may be supplied to the reactor via theshowerhead so that a suitable coverage of a surface active speciesderived from the process feed is generated on a process surface of thesubstrate.

At 1706, method 1700 includes adjusting a temperature of the processfeed within a showerhead volume upstream of the showerhead by supplyinga heat exchange fluid to a heat exchange fluid channel into which aplurality of heat exchange structures extend so that the heat exchangefluid flows between and above the heat exchange structures within theheat exchange fluid channel, the heat exchange structures beingthermally coupled with the showerhead volume.

In some embodiments, adjusting the temperature at 1706 may include, at1708, receiving a temperature of a heat exchange surface from which theheat exchange structures extend from a temperature sensor thermallycoupled with the heat exchange surface. For example, process feedtemperature information may be received from one or more temperaturesensors. If a temperature of the process feed is judged to be too lowrelative to a predetermined temperature, action may be taken to raisethe temperature of the heat exchange surface so that a temperature ofthe process feed within the showerhead may be raised. Alternatively, ifa temperature of the heat exchange surface is judged to be too highrelative to a predetermined temperature, a different action may be takento lower the temperature of the heat exchange surface so that thetemperature of the process feed within the showerhead volume may belowered.

For example, in some embodiments, method 1700 may include, at 1710,adjusting a power supplied to a heating element included in the heatexchange surface. In a scenario where the heat exchange surface exceedsthe predetermined temperature, the power supplied to the heater may bereduced. Alternatively, in a scenario where the heat exchange surface isless than the predetermined temperature, the power supplied to theheater may be increased. It will be appreciated that almost any suitablemethod of controlling the heater power may be employed without departingfrom the scope of the present disclosure, including control schemes thatinclude one or more of proportional, derivative, and integral elements.

As another example, in some embodiments, method 1700 may include, at1712, adjusting power supplied to a blower or pump configured to supplyheat exchange fluid to the heat exchange surface. In a scenario wherethe heat exchange surface exceeds the predetermined temperature, thepower supplied to the blower or pump may be reduced. Alternatively, in ascenario where the heat exchange surface is less than the predeterminedtemperature, the power supplied to the blower or pump may be increased.It will be appreciated that almost any suitable method of controllingthe blower or pump power may be employed without departing from thescope of the present disclosure, including control schemes that includeone or more of proportional, derivative, and integral elements.

In some embodiments, the heater and the blower or pump may be operatedconcurrently. For example, in one scenario, a blower may provide coolair continuously while a heater power is adjusted to vary heat input tothe heat exchange surface. In another scenario, a heater may provide acontinuous heat input while a blower power is adjusted to vary coolingprovided to the heat exchange surface. In yet another scenario, bothheater and blower power may be adjusted concurrently to control heatingand cooling of the heat exchange surface.

In some embodiments, method 1700 may be performed by a system processcontroller comprising a data-holding subsystem comprising instructionsexecutable by a logic subsystem to perform the processes describedherein. Virtually any suitable system process controller may be employedwithout departing from the scope of the present disclosure.

For example, FIG. 2 shows an embodiment of a system process controller202 provided for controlling semiconductor process module 100. Systemprocess controller 202 may operate process module control subsystems,such as gas control subsystems, pressure control subsystems, temperaturecontrol subsystems, electrical control subsystems, and mechanicalcontrol subsystems. Such control subsystems may receive various signalsprovided by sensors, relays, and controllers and make suitableadjustments in response.

System process controller 202 comprises a computing system that includesa data-holding subsystem and a logic subsystem. The data-holdingsubsystem may include one or more physical, non-transitory, devicesconfigured to hold data and/or instructions executable by the logicsubsystem to implement the methods and processes described herein. Thelogic subsystem may include one or more physical devices configured toexecute one or more instructions stored in the data-holding subsystem.The logic subsystem may include one or more processors that areconfigured to execute software instructions.

In some embodiments, such instructions may control the execution ofprocess recipes. Generally, a process recipe includes a sequentialdescription of process parameters used to process a substrate, suchparameters including time, temperature, pressure, and concentration,etc., as well as various parameters describing electrical, mechanical,and environmental aspects of the tool during substrate processing. Theinstructions may also control the execution of various maintenancerecipes used during maintenance procedures and the like. In someembodiments, such instructions may be stored on removablecomputer-readable storage media, which may be used to store and/ortransfer data and/or instructions executable to implement the methodsand processes described herein. It will be appreciated that any suitableremovable computer-readable storage media may be employed withoutdeparting from the scope of the present disclosure. Non-limitingexamples include DVDs, CD-ROMs, floppy discs, and flash drives.

It is to be understood that the configurations and/or approachesdescribed herein are exemplary in nature, and that these specificembodiments or examples are not to be considered in a limiting sense,because numerous variations are possible. The specific routines ormethods described herein may represent one or more of any number ofprocessing strategies. Thus, the various acts illustrated may beperformed in the sequence illustrated, in other sequences, or omitted insome cases.

The subject matter of the present disclosure includes all novel andnonobvious combinations and subcombinations of the various processes,systems and configurations, and other features, functions, acts, and/orproperties disclosed herein, as well as any and all equivalents thereof.

1. A semiconductor process module comprising a reactor, wherein thereactor comprises a gas channel plate, the gas channel plate comprising:a heat exchange surface including a plurality of heat exchangestructures separated from one another by intervening gaps; and a heatexchange fluid director plate support surface for supporting a heatexchange fluid director plate above the plurality of heat exchangestructures so that at least a portion of the plurality of heat exchangestructures are spaced from the heat exchange fluid director plate. 2.The semiconductor process module of claim 1, further comprising aprocess feed inlet for supplying a process feed to a showerhead volumeformed between a diffusion surface disposed opposite the heat exchangesurface and a showerhead sealably coupled to the gas channel plate. 3.The semiconductor process module of claim 1, where the process feedinlet includes a flow expansion structure upstream of the process feedinlet, the flow expansion structure being aligned with a centerline ofthe process feed inlet.
 4. The semiconductor process module of claim 1,where the flow expansion structure includes a concentric conicalexpansion formed on an inner surface of the flow expansion structure. 5.The semiconductor process module of claim 1, further comprising a purgegas channel fluidly communicating with an ambient environment at alocation between the ambient environment and a gasket disposed betweenthe gas channel plate and a pulse valve manifold positioned upstream ofthe gas channel plate.
 6. The semiconductor process module of claim 1,where the diffusion surface has a radially symmetric profile withrespect to a centerline of the gas channel plate, the diffusion surfacebecoming closer to the showerhead as distance from a centerline of thegas channel plate increases.
 7. The semiconductor process module ofclaim 1, where the radially symmetric profile includes a portion of thediffusion surface being disposed at an angle of between 0 and 5 degreeswith respect to a reference plane defining a widest portion of theshowerhead volume.
 8. (The semiconductor process module of claim 1,where the diffusion surface has a radially symmetric profile withrespect to a centerline of the gas channel plate, where the radiallysymmetric profile includes a portion of the diffusion surface disposedat an angle of between 0 and 5 degrees with respect to a reference planedefining a widest portion of the showerhead volume, and where an uppersurface of the showerhead facing the showerhead volume is spaced fromthe portion of the diffusion surface so that the portion of thediffusion surface and a respective portion of the upper surface remain aconstant distance apart as distance from a centerline of the gas channelplate increases.
 9. The semiconductor process module of claim 1, wherethe gas channel plate is sealably coupled to the showerhead by a gasketpositioned within 20 mm of a showerhead distribution hole included inthe showerhead.
 10. The semiconductor process module of claim 1, furthercomprising: a heating element disposed in a spiral groove included inthe heat exchange surface; a temperature controller electricallyconnected with the heating element for adjusting a temperature of theheating element in response to a temperature of the heat exchangesurface.
 11. The semiconductor process module of claim 10, where theshowerhead includes a heating element independent from the heatingelement included in the heat exchange surface.
 12. A semiconductorreactor comprising a gas channel plate, wherein the gas channel platecomprises: a heat exchange surface including a plurality of heatexchange structures separated from one another by intervening gaps; anda heat exchange fluid director plate support surface for supporting aheat exchange fluid director plate above the plurality of heat exchangestructures so that at least a portion of the plurality of heat exchangestructures are spaced from the heat exchange fluid director plate. 13.The semiconductor reactor of claim 12, further comprising a process feedinlet for supplying a process feed to a showerhead volume formed betweena diffusion surface disposed opposite the heat exchange surface and ashowerhead sealably coupled to the gas channel plate.
 14. Thesemiconductor reactor of claim 13, where the process feed inlet includesa flow expansion structure upstream of the process feed inlet, the flowexpansion structure being aligned with a centerline of the process feedinlet.
 15. The semiconductor reactor of claim 14, where the flowexpansion structure includes a concentric conical expansion formed on aninner surface of the flow expansion structure.
 16. A processing toolcomprising the semiconductor process module of claim
 2. 17. A gaschannel plate for a semiconductor process module, the gas channel platecomprising: a heat exchange surface including a plurality of heatexchange structures separated from one another by intervening gaps; anda heat exchange fluid director plate support surface for supporting aheat exchange fluid director plate above the plurality of heat exchangestructures so that at least a portion of the plurality of heat exchangestructures are spaced from the heat exchange fluid director plate.
 18. Agas channel plate for a semiconductor process module, the gas channelplate comprising: a heat exchange surface including a plurality of heatexchange structures separated from one another by intervening gaps; anda heat exchange fluid director plate support surface for supporting aheat exchange fluid director plate above the plurality of heat exchangestructures so that at least a portion of the plurality of heat exchangestructures are spaced from the heat exchange fluid director plate. 19.The gas channel plate of claim 18, further comprising a process feedinlet for supplying a process feed to a showerhead volume formed betweena diffusion surface disposed opposite the heat exchange surface and ashowerhead sealably coupled to the gas channel plate.
 20. At a processcontroller of a semiconductor process module, a method for processing asemiconductor substrate in a reactor of a semiconductor process module,the method comprising: supporting the substrate with a susceptor withinthe reactor; supplying a process feed to the reactor vm a showerheadpositioned above the substrate; and adjusting a temperature of theprocess feed within a showerhead volume upstream of the showerhead bysupplying a heat exchange fluid to a heat exchange fluid channel intowhich a plurality of heat exchange structures extend so that the heatexchange fluid flows between and above the heat exchange structureswithin the heat exchange fluid channel, the heat exchange structuresbeing thermally coupled with the showerhead volume.